Method of producing nested floor panels



Aug. 15, 1961 P. N. Youn 2,995,799

METHOD OF FRODUCING NESTED FLOOR PANELS Filed Oct. 3, 1956 4Sheets-Shay:l 1

Aug. l5, 1961 v P. N. YoUTz 2,995,799

METHOD OF PRODUCING NESTED FLOOR PANELS Filed Oct. 3, 1956 4Sheets-Sheet 2 Afro/ewfy Aug. 15, 1961 P. N. YouTz METHOD OF' PRODUCINGNESTED FLOOR PANELS 4 Sheets-Sheet 3 Filed Oct. 5, 1956 Aug. 15, 1961 P.N. YOUTZ 2,995,799

METHOD OF PRODUCING NESTED FLOOR PANELS Filed Oct. 5, 1956 4Sheets-Sheet 4 2,995,799 ll/mTHOD OF PRODUCING NESTED FLOOR PANELSPhiiip N. Youtz, Spring Road, Yorktown Heights, N.Y.

Filed Oct. 3, 1956, Ser. No. 613,658 2 Claims. (Cl. 2S154) Thisinvention relates to building construction and especially to theconstruction of buildings having a steel frame and concrete floorssupported by the horizontal beams and girders of the frame.

One method of erecting a building having a plurality of stories andconstructed with a steel frame and concrete floors is to rst erect thesteel framework and then to cast the concrete floors for the individualiloor levels of each bay of the building at ground level and one on topof another to provide a stack of floor panels, each floor panel being ofa size and shape to provide a complete upper lloor for any bay of thebuilding.

After the stack of separate floor panels has been cast then each floorpanel from the stack is raised to an upper level by means of a crane orother suitable device and is placed on the framework at said desiredlevel thereby providing a complete concrete floor for a bay of thebuilding at such level. The method above set forth is disclosed in myU.S. Patent 2,721,533 dated February 3, 1959.

The invention described in the present application Ser. No. 613,658relates to a novel method of casting the floor panels for a buildingsuch as referred to above, and it includes casting the yfloor panels inpairs, each pair of floor panels being cast in such a nested relationthat the combined thickness of the two floor panels of a pair in theirnested relation is the same as that of each individual panel of thepair.

The -floor panels herein shown are of that type in which each panel hasa central body portion of uniform thickness and also has two oppositeedge portions which are thicker than the body portion.

As stated above the novel method by which the floor panels are castinvolves casting said floor panels in pairs with the two floor panels ofeach pair having such a nested relation that when the two floor panelsare separated each floor panel constitutes a complete iloor for a bay ofthe building at any desired level. Each pair of nested floor panelspresents a unit which has a uniform thickness equal to the thickness ofthe thickened edge portions of the separate panels.

Referring to the drawings:

FIG. 1 is a plan view of 4a pair of nested floor panels after they havebeen poured in their nested relation;

FIG. 2 is a section on the line 2 2, FIG. 1;

FIG. 3 is a section on the line 3 3, FIG. 1;

FIGS. 4 and 5 are sectional perspective views showing a plurality ofpairs of nested panels which have been poured to form a stack of panels,FIG. 4 showing the stack of panels in section corresponding to thesection line 3 3, FIG. l and FIG. 5 showing the stack of nested panelsin section corresponding to the section line 3 3, FIG. l;

FIG. 6 is a fragmentary perspective view showing one end of one of thefloor panels of the pair in the position in which it will assume whenlaid in the lfloor of the building;

FIG. 7 is a fragmentary perspective -view showing one end of the otherpanel of each pair;

LFIG. 8 is a plan view illustrating the portion of a floor of a buildingcomposed of the floor panels shown in FIG. 1 and illustrating theirrelative position;`

FIG. 9 is an enlarged fragmentary view showing one of the columns of thebuilding in section and illustrating the manner in which the variousfloor panels are attached thereto;

FIG. 10 is a perspective view illustrating the construction shown inFIG. 9.

One way to cast the panels in pairs with the panels of each pair havinga nesting relation is shown in FIGS. 1, 2, and 3 wherein the two panelsof a pair are indicated at A and B. The panel A is first poured, and anysuitable llat surface such as the ground Hoor or lowest floor in one ofthe bays of the building being erected may be used for this purpose, itonly being necessary to use edge forms in connection with such flatsurface to provide a complete form for said panel. The floor panel A hasa at central or body portion 2 which is properly reinforced withreinforcing rods (not shown) in accordance with conventional practice,and it also has two opposite raised edge portions 3 which are thickerthan the body portion. Each thickened edge portion 3 has a steel beam oriloor supporting element 4 embedded therein.

The floor panel A is cast with a notch 5 at each corner, and the ends 4aof the beams 4 project into the notches and provide means by which saidbeams can be secured to the columns 1 when the oor panel had been raisedto its permanent position in the building, as will be hereinafterexplained.

The extra thickness of the edge portions 3 extends such edge portionsabove the body 2 by a distance equal to the thickness of said body asshown in FIG. 2 and the outer face of each edge portion '3 is providedwith an outwardly extending rib or ledge 6. The floor panel may also becast with a central opening 7, if desired, for a purpose presently to bedescribed.

When the floor panel A has set suiliciently, the cornpanion oor panel Bis poured directly on the panel A, any suitable means being used toprevent the two panels from becoming bonded together. One well knowntechnique for this purpose would be to cover the top surface of panel Awith so-called release material and then to pour the panel B on therelease material. The shoulders 8 which result from making the thickedge portions 3 of panel A constitute the edge forms for two oppositeedges 9 of the panel B. The other two opposite edge portions 10 of thepanel lB overhang the edges 11 of the panel A and are thickened as shownin FIG. 3 so that the bottom face 12. of each thickened edge portion 10is ilush with the bottom face 13 of the floor panel A. Each thick edge10 of the panel B has a steel beam 14 embedded therein and the ends 15of such beams project into the notches 5. The thickened edge portions 10are provided with outwardly projecting ribs or ledges 17, as shown inFIG. 3 and each of the floor panels `B may also be cast with a centralopening 7.

It will be understood that suitable edge forms will be used to giveproper shape to the outer face of the thick edges 10 of each panel B,these being the only forms in addition to that provided by thepreviously cast panel A that are necessary to cast said panel B.

The two floor panels A and B when in their nted relation, as shown inFIGS. 1, 2, and 3, present a fiat top surface on which another pair ofsimilar nested floor panels can be cast, a shown in FIGS. 4 and 5.

These pairs of nested floor panels may be cast at ground level on any atsurface. The lowest floors in the several bays of the building beingerected provide such flat surfaces, and when the requisite number ofpairs of floor panels have been formed and have set suiciently, then theindividual floor panels are raised to higher floor levels and attachedto the columns 1 of the steel frame of the building.

The raising of the individual oor panels ,to their permanent position inthe building may be done by a crane of the type commonly used inerecting the steel frame of the building. In the case of the floor panelA of a nested pair it is necessary to invert it so that its smooth face13 will be the oor top surface and the opposite surface will be theunderside of the floor panel. When any baysize floor panel has been thusraised to an elevated position and placed in the bay which it is tooccupy permanently, the four columns 1 defining the bay will occupy thefour notches 5 of the elevated oor panel. When the floor panel is in itsproper position and at the correct elevation, then the ends of beams 4and 14 carried b-y the floor panel are secured to the columns 1, andthis may be done in any suitable way either by welding the ends of thebeams to the columns or by means of angles 16 which are bolted orriveted to the projecting ends of the beams carried by the raised oorpanel into the column, as shown in FIGS. 9 and 10. To assist in holdingany raised oor panel in its correct position while the beams embeddedtherein are being attached to the columns, the latter may be providedwith properly placed shelf angles on which the projecting ends of thebeams in the raised floor panel may rest while the attaching angles 16are being secured to the columns and to the beam ends.

The construction of the floor panels A and B is such that when they arelaid to provide a oor of a building having several bays said oor panelsA and B are arranged alternately in each row of bays.

Upon referring to FIG. 8 it will be seen` that in the top horizontal rowof complete bays the oor panels are arranged with a panel B at the rightend of said top row adjacent the wall of the building and a panel A isthe next panel to the left, while the third panel to the left is anotherpanel B, and so on. 'I'he same alternate arrangement of floor panels Aand floor panels B appears in each vertical row of bays.

When these floor panels A and B have been laid as shown in FIG. 8 itwill be observed that each of the two opposite edges 9 of any panel Brests on a ledge or rib 6 of the adjacent panel A, while each of the twoopposite edges 11 of any panel A rests on a shelf or ledge 17 providedby an adjacent floor panel B.

With this arrangement each beam 4 embedded in a thickened edge portionof a oor panel A supports not only said edge of the panel A b-ut theadjacent edge of the adjacent floor panel B, and each supporting beam 14which is embedded in an edge of the floor panel B serves to support notonly said edge of floor panel B but the adjacent edge 11 of an adjacentfloor panel A.

I claim.:

1. The method of producing a pair of separate, individual rectangularconcrete oor panels in a nested relation which consists in forming afirst complete rectangular iioor panel which has a at bottom face and auniform thickness except at two opposite edges where the twocorresponding edge portions rise above the portion of uniform thicknessby an amount equal to such thickness, applying release material to thetop face of said first rectangular panel, forming a second complete andindependent rectangular oor panel directly on said first panel in anested relation therewith, which second panel is provided with a bodyportion of uniform thickness that lls the space between the raised edgeportions of said first panel and has a flat top face which is ush withthe top face of said raised edge portions, and which also has twooppositely disposed depending edge portions each of which is outside ofand overlies the face edge of a nonthickened edge portion of the firstiioor panel and has its bottom face iiush with the at bottom face ofsaid rst oor panel, whereby the distance between the top and bottomfaces of the two oor panels in their nested relation is the same as thedistance between the top and bottom face of each individual floor panel.

2. The method of producing a pair of rectangular concrete oor panels asdefined in claim 1 and which includes embedding a steel beam in each ofthe two raised edge portions of the iirst oor panel while it is beingformed and also embedding a steel beam in each of the depending edgeportions of the second oor panel as the latter is being formed.

References Cited in the file of this patent UNITED STATES PATENTS461,890 Richardson Oct. 27, 1891 992,739 Meier May 16, 1911 1,066,436Peltzer July 1, 1913 1,463,841 Richman Aug. 7, 1923 1,473,200 SawyerNov. 6, 1923 1,592,070 Blake July 13, 1926 2,115,949 Gurger May 3, 19382,499,532 Shearer Mar. 7, 1950 2,505,152 Shearer Apr. 25, 1950 2,531,990Rappoli Nov. 28, 1950 2,720,017 Youtz Oct. 11, 1955 FOREIGN PATENTS'43,274 Switzerland Dec. l, 1907

